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Probably need to stop buying certain types of tools off eBay. The ones pictured looks like real taps. The one that broke doesn’t.

True. If they aren't hardened steel, probably isn't necessary to use left handed bit. Although it might easily unscrew the broken portion with the LH bit. Have you tried unscrewing the piece with a small screwdriver. Sometimes the piece isn't hard to turn.

You probably aren't going to drill into a tap. Typically, the tap is going to be much harder than a drill bit and as you have learned they can be brittle. Sometimes you can use a punch and hammer and smack them, and they will break into smaller pieces. Or you can try to use a die grinder with a...

Couple of related threads http://dfkitcar.com/forum/index.php?threads/no-crank-when-headlights-off.4848/ http://dfkitcar.com/forum/index.php?threads/no-start-issue-b-terminal-fuse-box.3845/post-77180

I think there is a back feed into the bcm from the head light circuit that allows it to start even with a blown fuse that should keep it from starting.

I think there is a fuse on the bcm being shot causes this. Anyone remember which one it is? I know it’s more than 1 no-start that I walked through.

Grundy Insurance

Not sure what you are shooting for as a final product but I think 1/16 inch aluminum is going to vibrate like crazy with that much overhang. And can you climb in with that side overhang?

Nutserts in the halo bar. I think I just laid the sheet on the top and marked the halo and adjusted off those lines. Yes, blue bars are reinforcement. Not sure how necessary it is but helps distribute the load and not use as large a washer. Hard part is getting the holes centered and nutserts...

And polycarbonate is also available in opaque colors. Mine was black. You could also probably use ABS or PVC sheets.

Picture http://dfkitcar.com/forum/index.php?threads/desert-sasqwatch-155-track-mods-08-ss-tc-crate-lnf-f40.1003/post-87622 Paint works pretty good on polycarbonate. Vinyl wrap sticks pretty good also. I also put boat carpet on the bottom, mostly as padding to protect the halo bar paint. I used...

And I just checked and mine sticks out about 5 inches from the center of the halo bar.

I overhung mine but I also had to add a reinforcement bar under it. The whole roof vibrated at high speeds (above 90mph) I don’t know that it was caused by the overhang but seems likely.

Have you confirmed every fuse on the main fuse panel and BCM is good? If so, my first step would be to check every 12v supply wire on the ECM and BCM is getting power. I would do this by back probing the connector but that means you will need back probing ends for your DVOM. And use a 100%...

Never said it was cheaper. Just that it was reasonable and can be worked with simple tools. Depending on thickness, it's about $100 or less for a 24"x48" sheet. Seems a reasonable cost for a roof.

Polycarbonate can work pretty well for a roof panel. Not to bad a price if purchased from Grainger and picked up at a local store. And can be worked with a jig saw and belt sander.

Since the resistance checks out it’s doubtful there is a break in the wiring. It sounds like at least some of the modules are not waking up. What modules will BlueDriver read?

Starter positive to ground should spark and if you aren’t careful you’ll burn yourself or melt something. Starter positive to the solenoid signal wire (purple?) should check the starter function. But you need to get more organized in your troubleshooting. You are going to have trouble if you...

Hard to troubleshoot this when every time you read something you get different values. Somewhere around 60ohms is correct for the high speed data wires. Do you know why you have a 60 now and something different before?

Was the NA donor an automatic car? You definitely need to follow up on the no resistance on pin 6-14. This indicates a break in the high speed data wires. You also may have an issue on pin 6 of the ignition switch. That is 5v supply from the bcm to the switch so a voltage drop may indicate a...